Preparation of Al2O3 magnetic abrasives by gas-solid two-phase double-stage atomization and rapid solidification

This paper describes the production of Al2O3 magnetic abrasives via a double-stage atomization method. The matched pressures of atomization were simulated via Ansys-Fluent commercial software. The structure, phase composition and properties of the abrasives were examined. The analysis indicates that the magnetic abrasives have ideal spherical shape, and the Al2O3 hard particles are uniformly embedded into the surface of the iron matrix. The Al2O3 magnetic abrasives have good soft magnetic properties, with a saturation magnetization of 119 emu/g and a coercivity of 2.287 Oe. In addition, a series of plane magnetic abrasive finishing experiments were conducted using magnetic abrasives. The result of the Inconel718 plate shows that the developed abrasives have excellent processing performance, high grinding efficiency and long service life. Moreover, the atomization method described here could be promising for large-scale industrial preparation technologies.